Building wall construction



March 1 F. w. sT EvE s' I BUILDING WALL CONSTRUCTION Filed July 13, 1939 6 Sheets-Sheet 1 FRANK W. STEVE/VS March 1,1 F. w. STEVENS 2,344,749

BUILDING WALL CONSTRUCTION Filed July 13, 1939 6 Sheets-Sheet 2 FRANK VV- STEVE/VS March 1944- F. w. STEVENS BUILDING WALL CONSTRUCTION Filed July 13, 1939 6 Sheets-Sheet 3 3mm FRANK W STEVENS March 1944- F. w. STEVENS BUILDING WALL CONSTRUCTION Filed July 15, 1939 6 Sheets-Sheet 4 h t a m a I u I M. i/ mun March 21, 1944. w STEVENS 2,344,749

BUILDING WALL CONSTRUCTION I Filed July 13. 1939 e Sheets-Sheet 5 k i 4 14 I 1 I 1 1 vuawkvb March 21, 1944. F. w. STEVENS BUILDING WALL CONSTRUCTION Filed July 13, 1959 6 Sheets-Sheet 6 M r m c W w FRANK W STEVENS Patented Mar. 21, 1944 UNITED STATES PATENT OFFICE BUILDING WALL CONSTRUCTION Frank W. Stevens, Syracuse, N. Y. Application July 13, 1939, Serial No. 284,353

8 Claims.

This invention relates to a building construction and method that is adapted to provide a multiplicity of heat and dampness insulating cells within the building wall, while at the same time reinforcing the construction.

The invention is equally well adapted for outside walls, partitions, floors, and roofs, and where the term Wall is used hereinafter it is intended, unless otherwise limited, to include all of these. The invention comprises a novel construction and method of using elements of sheet material to provide individual insulating cells within the walls that are separated from one another, and with wall ties of sheet material that reinforce the wall and hold the portions thereof at opposite sides of the insulating cells securely assembled, while at the same time serving t5 separate the insulating cells one from another. The sheet material employed in carrying out the invention may be sheet iron or steel, or other metal, or it may be Water proofed card board, suitably reinforced if desired, or any other sheet material having a requisite factor of strength and stability. The sheet elements that are assembled to make up the insulating units are of simple and easily produced form and may conveniently be delivered to the building location. as plain flat sheets to facilitate shipping and handling; such sheets to be shapedor cut or both, right on the construction job, with but little special equipment for this purpose. This method of procedure is also advantageous since it eliminates the necessity for carrying various sizes and shapes of the unit elements in stock. As to these insulating cell unit elements, it is to be noted that the smaller the 1 individual hollow cells that are formed in the wall construction, the lighter may be the material from which the core or cell unit is made. The invention is well adapted, and as herein shown, for in concrete building construction, but in its major aspects is also adapted for other types and materials for building.

It is to he noted that while the hollow insulating cells produced in. bu lding walls according to my invention, are of high heat insulating efficiency by reason of the dead air spaces provided, they may if desired be filled with insulating material either in solid form, such as asbestos, or they may be filled with a suitable chemical or gas teri ncre from the ml 0 n o. a1 connection with the accompanying drawings :1" cup ion taken in shown in Figure 1 but with a modification proin perspective showing a portion of the wall built up with the core units of Figure 1, and with the transverse wall ties assembled into the wall in a vertical position;

Figure 3 is a similarperspective and sectional view showing an arrangement wherein the wall ties are placed into the wall in a horizontal position;

Figure 4 is a perspective view showing a modified form of core unit elements wherein these elements are shaped and adapted to form double cells in the wall;

Figure 5 is a similar perspective view of the core unit elements showing them shaped and assembled to form triple cells in the wall;

Figure 6 is a transverse section showing a modified form of core or cell unit partially assem-r bled into a wall;

Figure 6a is a perspective view of one of the cell elements as employed in Figure 6;

Figure 7 is a horizontal section of a wall por-. tion showing still another form of core or cell unit built into a wall to provide insulating cells;

Figure "In is a perspective view of one of the cell unit elements of the form of Figure 7;

Figure 7b is a similar perspective view showing a cooperative cell element for use with the same form;

Figure 8 is a sectional view of a wall portion showing in perspective a still further modified form of core units which are here adapted to dove-tail or interfit one into another;

Figure 8a is a perspective view of .a core unit element as employed in the form of the invention shown in Figure 8; v

Figure 9 is a transverse section of wall structure employing generally the form of cell units tion showing provision for embedding necessary pipes and conduits in the concrete in connection with the use of the cell units of my invention;

Figure 11 is a horizontal section of a corner portion of a wall showing an adaptation of my invention thereto;

Figure 12 is a horizontal section of a wall portion at the locality of a partition showing an adaptation of my invention to provide strength and homogeneity with provision for the hollow cell units in both the main wall and the partition;

Figure 13 is a sectional-view of a concrete floor portion showing in perspective a core unit assembly of my invention embedded therein, this view also showing an aligning key that may be used in the operation;

Figure 14 is a transverse section of a portion of a wall and floor, showing the connection of the floor to the wall;

Figure 14a is a fragmentarytransverse section similar to Figure 14, but showing a still further modification of cell 'unit that may be employed in the floor;

Figure 15 is a vertical section at a corner of the top of the building showing a connection of the vertical wall to a relatively fiat roof, both wall and roof equipped with the cell units of my invention which are arranged to provide a homogeneous construction at this level;

Figure 16 is a sectional view similar to Figure 15 but showing the application of the invention to a gable or like relatively steep roof;

Figure 17 is a fragmentary horizontal section showing a jamb construction for casement windows embodying the invention;

Figure 18 is a similar fragmentary section showing the application of the invention to a sill construction for casement windows;

Figure 19 is a fragmentary transverse section showing a jamb construction for sash windows;

' units of my invention are produced by providing sheet material elements I having an intermediate portion from the sides of which are bent' in opposite directions at right angles, portions Illa, lb. The lower extending portion lllb may have ears ll struck inward.therefrom adjacent its opposite sides while the upper extending portion Illa may have similar ears l2 struck outward, therefrom. The lowermost one of these' elements is embedded in the footing somewhat, as indicated at l3 and other like elements are erected thereupon, the ears ll, if used, resting upon the intermediate horizontal portion III of the next .lower element, while the other side of the intermediate portion of the element rests upon the indicated. In some instances it may be advan tageous to tack-weld units together, or use one.

of the well-known liquid cements, or a dash of mortar to hold units in position until the concrete is poured. These cell elements I0 may be 2, may be provided with a series of apertures or outwardly extending cars 12 .of the next lower element. The ears II and I2 are not requisite but assist in positioning the units in uniform. relation to one another. Thus these elements are adapted to build up a series of hollow cells intermediate the width of the wall, and these may be built up only as fast as the concrete is filled in, or they may be built up ahead of the concrete with the provision of spacers or wedge members S which fit between them and the wall forms a projections for more secure embedding in the concrete. These wall tie plates have the purposes, (l) of binding the double concrete wall and the hollow cells into a composite whole; (2) of comprising the ends of the hollow cells, thus becoming a part of the cells; and (3) of reinforcing the concrete.

The reinforcement thus produced by such metal wall tie is much more efiicient than a similar amount of metal in any other form, because it contacts a greater amount of concrete and the contact is continuous.

In Figure 3 I show a form of the invention where the hollow cell elements It corresponding to the elements 10, and similarly produced, are

set vertically instead of horizontally. In this.

case the wall ties or dividing plates are, of course, horizontally disposed. These plates ll are shown in this form as having flanged sides Ila for more secure engagement with the concrete, it being understood that either such flanges, or the apertures I 5, or both may be employed in either formof the invention. In this case as in that of Figure 1, a continuous series of individually isolated insulating cells is provided throughout the extent of the wall and intermediate the sides thereof.

In Figure 4 I show a form where the cell unit elements indicated at l8 are adapted to be built up into a double cell unit, such element being in this case produced with four rectangular bends successively in opposite directions as indicated at 18a, 18b, l8c,'|8d. These may be provided with struck out ears similarlyas the ears II, I2 and built upon one another as seen to provide a double hollow cell wall.

In Figure 5 I show a form wherein the metal plates which form the cells are adapted to provide triple cells in the wall, each plate 19 for this purpose having six rectangular .bends 19a, I91), I90, I9d, l9e, l9f; these elements being built up in the same manner as already described. This type oi construction is particularly useful in cases where the wall is composed entirely or mostly of such cell unit assembly, i. e., without any substantial amount of concrete or other material at the sides thereof, or where such assembly is covered with but a thin material layer such as plaster, stucco, shingles, or the like. tiple cell method of construction also provides more effective insulation, which makes it especially desirable for refrigerating purposes,.warehouses, etc.

In Figures 6 and 611 I show a form wherein the cell unit elements are inverted U-shaped as indicated at 20. These are adapted to be nested one upon another to a small extent as indicated at 2| so that the frictional hold thus obtained is suflicient to keep them relatively in place as they are built up from the base B with the concrete deposit Capplied at each side thereof as This mulin the forms already described, or ears such as H or 12 may be used. It will be understood that in this form as in each of the previous forms,

transverse'wall tie plates are interposed. between abutting ends of these elements 20 to form indi vidually isolated cells.

. In the form of the invention shown in Figures 7, 1a, and 7b the ,cell unit elements are formed of U-shape as indicated at 22 with flange portions 22a extending from each extremity of the U-porticn. These are assembled with the flange portions'22a of each element extending a small distance over the base of the U.-portin of the next adjacentelement as indicated at 23. This, of course, leaves the opening of the U-portions uncovered .and plates 26 are provided for application to cover these spaces so that they provide In this form also it alternate ones 'of the 'cells. will be understood that transverse wall tie plates are assembled with the described members similarly as in the prior described forms to provide isolated insulation cells, and tie the wall portions together. In Figures 8 and So I show a form wherein the cell unit elements are formed of in.-

verted U-shape'as seen at 25, but with grooves or'creases 26 formed at the sides of the base of such U-shape so that the edges of the side portions of the next element are adapted to interfit' with, or dove-tail into such grooves as indicated at 21.

The transverse wall tie plates are I 3 approximately in the diagonal direction of the corner as indicated at 38a, 29a and between them another, wall tie plate MLfshown'as somewhat longer. may extend in the diagonal directionof the corner.

In Figure 12 I show an. adaptation of the inventi on for the junction of inner partitions with here indicated at 28. In Figure 9 I show a form wherein cell elements it of Figure 1 are employed, but at the locatily of a protrusion-Pin the .wall a special cell ele-.

,ment 29 is: incorporated which is deeper. sons to extend afartherdistance into the protrusion P-, this element being otherwise formed so as to in terfitwith the elements l0.

In Figure 9a a special form of cell tion I in the wall, this unit differing from the elements l0 withwhichit is associated, only in element 33 is illustrated for use at the localitv of an indentabeing reduced in thickness 'as compared there- With. In Figure 10 I show an adaptation of the invention to a wall construction wherein various pipes, a I fines. and conduits may be incorporated in the wall and in a'novel associationwiththe insulating cells of my invention. In this case the hollow cellsmay be produced of elements 10 similarly as in the-'flrst described form with trans- I verse wall tie plates I4 as already described. As

illustrative'ly shown in this form a heating duct or flue 3| may take the place of one of the vertical cell unit; series.

Waste pipes, vents, or the like indicated at 32, 33 may' be incorporatedin the wall structure, the pipe 32being shown asv accommodated in an. inner protrusion 34 of the wall, while the pipe 33 is fitted intermediate the width of the-wall with one of the wall-tie plates H at each side thereof. The wall tie plate M located adjacent the pipe 32 may have a bent extremity 140 'to lie adjacent o. but clear the pipe 32. Other pipes as required. indicated at 35, and conduits 3B for various electric services may be embedded in the wall, a plug outlet for one of these being indicated at 31. r v v Figure 11.,shows an illustrativ application of my invention to the corner construction of walls. In this case the cell unit elements I0 leading up to the cornerjas already described, and the transverse wall-tie plates I! may be of a type already described. At the locality of the corner however, the mantle plates..3 8, 39 at the ends of the ad- .iacentcelhunitsfmay hg tbentso as to extend outer walls, the inner partition Al being illustratively shown as not so thick as the main wall. In such case the cell units. indicated at 42 may be correspondingly of less width, and the transverse wall tie plates'43 likewise of lessdimension.

"In such corner construction the wall tie, plates at the locality of suchjun'ction indicated at 44,.

45 may have an intermediate diagonal portion 46 extending across the corner with an extension 4? reaching into the concrete of thepartition. The V end of the cell units '42 at the locality of'the wall junctions may have an especially formed wall tie plate'48 with diagonally extending ends 48a ex- 1 tendin eeross the corner and spaced from the tie plate portions 46.

Fi ure '13 showsan illustrative application of my invention to fioor'c'onstructions. In this case alower layer 49 of concrete is first placed over the floor forms,-then cell unit elements 50 and wall tie plates 5|, similarly as already described, are insertedto some little depth into this concrete layer, while leaying a substantial open core area. i If desired, the reinforcing tie-plates 5! may be'of heavier material and extend from wall to wall to give strength to the floor. A second layer of concrete 52 is then appliedto' the top of the. core units. In practiceeach core unit should be lapped over the next one about an inches indicatedat'bt andthese overlapping areas may be securedtogethe'r by liquid cement, welding or otherwise.

It will be noted that the walltie plates bind the double layer'of concrete and the core unit assembly into a composite whole, and these tie plates comprise the ends of the .hollow cells likewise as-in the Vertical wall. It will also'be noted that both layers of concrete are reinforced by the core units at right angles to the tie plates. This produces an exceptionally strong floor, much in excess of ordinary needs. An aligning tool or key K may be provided so as to lock the core units and the wall ties at the proper level in, the lower concrete layer. This key has a hook or projection-K to engage the edges of the core unit elements, the core unit elements being pressed into the concrete until the end of the key reaches the floor form when the core unit or wall tie will-be held an inch or thereabouts above the floor form by the projection K, whereupon by'tu'rning the key until the projection is disengaged from the cell unit, the key may be removed.

In Figure 14 I show a form of core unit elements- 54 adapted for floor construction provided with a fiat portion 55 so located with respect to the extent of the unit element that is adapted to rest on the top of the first layerof concrete56 with the Y lower extremity-of the core elements 51 spaced the desired distanceabove the bottom of the concrete. The floor sleepers 58 for a top floor 59 of and providing two flat surfaces 62a, 52b to rest a floor H.

upon the lower layer of concrete, while also provlding a fiat surfaced upper extension 62c upon which the next adjacent core unit element may rest.-

In Figure 15 I show an illustrative application of the invention to the unction of a relatively flat roof 63 to a vertical wall 64. This is similar to the provision for the floors already described, ex-

cept that the hollow cells 65 produced by the core unit assembly 66 are formed thicker to provide more eflective insulation. It is to be observed that the cell unit elements 61, 68 at the locality of the juncture of the roof and the vertical wall are extended and bent so as to extend from the roof into the concrete of the vertical wall, and from the vertical wall into the concrete of the root respectively. In this Figure 14 indicates a portion of one of the wall tie plates.

Figure 16 illustrates the juncture of a steeper or gable roof 69 with an outer wall I0, and with This is accomplished similarly as already described, the cell unit elements at the locality of th angular bend from the wall to the roof having extender. projections 12, 13 into the mass of the concrete to further reinforce the same, and the cell unit elements 14 at the juncture of the floor with the wall also having ex-' tensions 15 to be embedded quite some distance v in the concrete of the wall.

Figure 17 illustrates a feature of construction adapted for the application of a casement window 16 with interposed caulking 11 against a ledge 18 of the concrete wall. tie unit may be provided with an intermediate portion to close the adjacent cell units 80, and with angularly bent extensions 79a, 19b to extend into the concrete at the locality of the jamb.

Figure, 18 shows another form of concrete reinforcement for the application of the casement window 16, this embracing angular extensions BI, 62 from the ends of the adjacent cell units and with an additional angular tie plate member 83 bent at an acute angle to reinforce the concrete to the best advantage.

Figure 19 illustrates a construction adapted for sash windows 84. In this case a reinforcing plate member 85 is provided with an intermediate portion adapted to rest against and close the'adjacent cell unit 86, and having at one end portion a right angular extension 81 through the concrete, and having the other end portion reversely bent as indicated at 81' with an acute angle extremity 88 to best reinforce the concrete at the locality of the jamb.

Figure 20 illustrates a windowv construction 'with a jamb 89 which may also be used for door jambs if desired. In this case the end .core unit assembly 90 has fitted thereto a reinforcing plate having an intermediate portion 9| to fit against the end of the cell unit with angular extremities 92, 93 to extend diagonally into the concrete mass.

It will thus be noted that in each of the described forms of the invention I provide hollow cell elements of simple-form that are adapted In this case a'bent wall.

to be shaped from fiat sheet material on the l use of material. Aconcret wall produced .as

the invention for roofs and floors as described.

I am aware that the invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof, and I therefore desire the present embodiment to be considered inall respects as illustrative and not restrictive, reference being had to the appended claims rather than to the foregoing description to indicate the scope of the invention.

Having now described my invention, what I claim as new and desire to secure by Letters Patcut is:

1. An insulating core assembly for building walls, comprising pieces of sheet material bent to angular form and interfltted one with another to constitute four sides of six-sided cells, and other pieces of sheet material fitted cross-wise in such assembly to close the remaining two sides of the cell units, said other pieces extending transversely outward from the cell unit assembly to constitute ties for embedding in cement, the entire assembly adapted to be embedded in plastic material.

2. A building wall having an interior insulating core with concrete or the like at each side of such core, said core composed of a multiplicity of angularly bent pieces of sheet material interfitted one with another to define four sides of six-sided cell units, and tie plates applied to such ing space in a building wall, comprising a series of rectangular elements of sheet metal each having two parallel, opposite, and substantially rectangular bends completely across the same and forming three planes, two of said planes adapted to form the igont and top 01' one cell-unit, and the third plane forming the back of the cell-unit next above, said elements interfitted one with another, and transverse tie plates placed at each open end of each said interfltted cell-unit assem-' bly to close said ends and make each such assembly form an individua1 dead-air space when the whole is embedded in concrete, the said tie plates projecting beyond the sides of the rest of the assembly 50 as to be embedded in the concrete and reinforce same.

4. An insulating core assembly for pouredconcrete building walls, comprising elements of sheet material each bent to angularform to constitute in itself three sides of a rectangular cell each of said elements interfltted with a like element constituting a fourth side of said cell, and tie plates placed transversely at each open end of said cell to complete same, said tie plates extending transversely beyond said-cell sides so as to be embedded in the concrete.

5. An insulating core assembly for pouredconcrete building walls, comprising elements of sheet material each bent to angular form to constitute in itself two sides of a rectangular cell and interfitted with a like element to constitute four sides of said cell, and tie plates placed transversely at each open end of saidcell to complete same, said tie plates extending transversely beyond the sides of said cells so as to be embedded in the concrete.

6. A building wall having an insulating core composed of amultiplicity of individual six-sided air cells with concrete or the like at each side or such core, each of said cells being formed by a rectangular element of sheet metal having two parallel, opposite, and substantially rectangular bends completely across the same and forming three planes, two of said planes adapted to form the front and top of one cell, and the third plane forming the back of the ce11 next above, said elements interfitted to form four sides of the cells, and tie plates applied to such assembly to rclose the other two sides or ends of the cell, said tie plates extending beyond the cell-unit assembly at each side thereof, the extended portions, of .said tie plates being embedded in th concrete to tie the concrete sides and the intermediate core together and reinforce the same.

7. A series of cell-unit elements for formin an insulating space in a building wall each comprising a strip of sheet material bent to substantially an inverted U shape with grooves formed along the top of the inverted U to receive and position the lower edges of another similar inverted U element and'the last-named element placed thereon to form four sides of a rectangu lar cell.

8. A six-sided cell-unit assembly for forming air cells in a poured-concrete building wall comprising rectangular elements of sheet material bent to substantially U shape and each inverted and interfitted on top of another such element to form four sides of a cell, and tie plates placed transversely at each end of such cell to form the other two sides and complete the cell, said tie plates projecting transversely beyond the said elements for embedding in the concrete.

FRANK W. STEVENS. 

